Mobile distribution station with additive injector

ABSTRACT

A distribution station includes a mobile trailer and a delivery system. The delivery system includes a pump, a manifold fluidly connected with the pump, reels, hoses, valves situated between the manifold and a respective different one of the hoses, and fluid level sensors. There is also an additive injector fluidly connected with the delivery system and operable to introduce controlled amounts of an additive into the delivery system.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present disclosure is a continuation of U.S. patent application Ser.No. 15/795,697 filed Oct. 27, 2017.

BACKGROUND

Hydraulic fracturing (also known as fracking) is a well-stimulationprocess that utilizes pressurized liquids to fracture rock formations.Pumps and other equipment used for hydraulic fracturing typicallyoperate at the surface of the well site. The equipment may operatesemi-continuously, until refueling is needed, at which time theequipment may be shut-down for refueling. Shut-downs are costly andreduce efficiency. More preferably, to avoid shut-downs fuel isreplenished in a hot-refueling operation while the equipment continuesto run. This permits fracking operations to proceed fully continuously;however, hot-refueling can be difficult to reliably sustain for theduration of the fracking operation.

SUMMARY

A distribution station according to an example of the present disclosureincludes a mobile trailer, a delivery system that has a pump on themobile trailer, a manifold on the mobile trailer and fluidly connectedwith the pump, a plurality of reels on the mobile trailer, and aplurality of hoses connected, respectively, with the reels. The reelsare fluidly connected with the manifold and each of the valves aresituated between the manifold and a respective different one of thehoses. Each of the sensors is associated with a respective different oneof the hoses. An additive injector is fluidly connected with thedelivery system and operable to introduce controlled amounts of anadditive into the delivery system.

A distribution station according to an example of the present disclosureincludes an injection system that has a controller and an additiveinjector fluidly connected with the delivery system. The controller isconfigured to operate the additive injector and introduce controlledamounts of an additive into the delivery system.

A distribution station according to an example of the present disclosureincludes a container that has an additive and an additive injectorfluidly connected with the container. The delivery system is operable tointroduce controlled amounts of the additive.

BRIEF DESCRIPTION OF THE DRAWINGS

The various features and advantages of the present disclosure willbecome apparent to those skilled in the art from the following detaileddescription. The drawings that accompany the detailed description can bebriefly described as follows.

FIG. 1 illustrates an example mobile distribution station.

FIG. 2 illustrates an internal layout of a mobile distribution station.

FIG. 3 illustrates an example of a connection between a manifold, acontrol valve, and a reel.

FIG. 4 illustrates an example of an integrated fuel cap sensor for amobile distribution station.

FIG. 5 illustrates another example mobile distribution station.

DETAILED DESCRIPTION

FIG. 1 illustrates a mobile distribution station 20 and FIG. 2illustrates an internal layout of the station 20. As will be described,the station 20 may serve in a “hot-refueling” capacity to distributefuel to multiple pieces of equipment while the equipment is running,such as fracking equipment at a well site. As will be appreciated, thestation 20 is not limited to applications for fracking or for deliveringfuel. The examples herein may be presented with respect to fueldelivery, but the station 20 may be used in mobile delivery of otherfluids, in other gas/petroleum recovery operations, or in otheroperations where mobile refueling or fluid delivery will be of benefit.

In this example, the station 20 includes a mobile trailer 22. Generally,the mobile trailer 22 is elongated and has first and second opposedtrailer side walls W1 and W2 that join first and second opposed trailerend walls E1 and E2. Most typically, the trailer 22 will also have aclosed top (not shown). The mobile trailer 22 may have wheels thatpermit the mobile trailer 22 to be moved by a vehicle from site to siteto service different hot-refueling operations.

In this example, the mobile trailer 22 has two compartments. A firstcompartment 24 includes the physical components for distributing fuel,such as diesel fuel, and a second compartment 26 serves as an isolatedcontrol room for managing and monitoring fuel distribution. Thecompartments 24/26 are separated by an inside wall 28 a that has aninside door 28 b.

The first compartment 24 includes one or more pumps 30. Fuel may beprovided to the one or more pumps 30 from an external fuel source, suchas a tanker truck on the site. On the trailer 22, the one or more pumps30 are fluidly connected via a fuel line 32 with a high precisionregister 34 for metering fuel. The fuel line 32 may include, but is notlimited to, hard piping. In this example, the fuel line 32 includes afiltration and air eliminator system 36 a and one or more sensors 36 b.Although optional, the system 36 a is beneficial in manyimplementations, to remove foreign particles and air from the fuel priorto delivery to the equipment. The one or more sensors 36 b may include atemperature sensor, a pressure sensor, or a combination thereof, whichassist in fuel distribution management.

The fuel line 32 is connected with one or more manifolds 38. In theillustrated example, the station 20 includes two manifolds 38 thatarranged on opposed sides of the compartment 24, with an aisle A inbetween. As an example, the manifolds 38 are elongated tubes that aregenerally larger in diameter than the fuel line 32 and that have atleast one inlet and multiple outlets. Each hose 40 is wound, at leastinitially, on a reel 42 that is rotatable to extend or retract the hose40 externally through one or more windows of the trailer 22. Each reel42 may have an associated motor to mechanically extend and retract thehose 40. The reels 42 and motors may be mounted on a support rack in thestation 20. The station 20 may include twenty hoses 40, although feweror more hoses could be used. Most typically, some of the hoses 40 aredeployable from one side of the station 20 and other hoses aredeployable from the other side of the station 20.

Referring also to FIG. 3, each hose 40 is connected to a respective oneof the reels 42 and a respective one of a plurality of control valves44. For example, a secondary fuel line 46 leads from the manifold 38 tothe reel 42. The control valve 44 is in the secondary fuel line 46. Thecontrol valve 44 is moveable between open and closed positions toselectively permit fuel flow from the manifold 38 to the reel 42 and thehose 40. For example, the control valve 44 is a powered valve, such as asolenoid valve.

In the illustrated example, the first compartment 24 also includes asensor support rack 48. The sensor support rack 48 holds integrated fuelcap sensors 50 (when not in use), or at least portions thereof. When inuse, each integrated fuel cap sensor 50 is temporarily affixed to apiece of equipment (i.e., the fuel tank of the equipment) that issubject to the hot-refueling operation. Each hose 40 may include aconnector end 40 a and each integrated fuel cap sensor 50 may have acorresponding mating connector to facilitate rapid connection anddisconnection of the hose 40 with the integrated fuel cap sensor 50. Forexample, the connector end 40 a and mating connector on the integratedfuel cap sensor 50 form a hydraulic quick-connect.

FIG. 4 illustrates a representative example of one of the integratedfuel cap sensors 50. The integrated fuel cap sensor 50 includes a capportion 50 a and a fluid level sensor portion 50 b. The cap portion 50 ais detachably connectable with a port of a fuel tank. The cap portion 50a includes a connector port 50 c, which is detachably connectable withthe connector 60 of the hose 40. The sensor portion 50 b includes asensor 50 d and a sensor port 50 e that is detachably connectable with aconnector. The fuel cap sensor 50 may also include a vent port thatattaches to a drain hose, to drain any overflow into a containmentbucket and/or reduce air pressure build-up in a fuel tank. Thus, a usermay first mount the cap portion 50 a on the fuel tank of the equipment,followed by connecting the hose 40 to the port 50 c.

The sensor 50 d may be any type of sensor that is capable of detectingfluid or fuel level in a tank. In one example, the sensor 50 d is aguided wave radar sensor. A guided wave radar sensor may include atransmitter/sensor that emits radar waves, most typically radiofrequency waves, down a probe. The probe serves as a guide for the radarwaves. The radar waves reflect off of the surface of the fuel and thereflected radar waves are received into the transmitter/sensor. A sensorcontroller determines the “time of flight” of the radar waves, i.e., howlong it takes from emission of the radar waves for the radar waves toreflect back to the transmitter/sensor. Based on the time, the sensorcontroller, or the controller 52 if the sensor controller does not havethe capability, determines the distance that the radar waves travel. Alonger distance thus indicates a lower fuel level (farther away) and ashorter distance indicates a higher fuel level (closer).

At least the control valves 44, pump or pumps 30, sensor or sensors 36b, and register 34 are in communication with a controller 52 located inthe second compartment 26. As an example, the controller 52 includessoftware, hardware, or both that is configured to carry out any of thefunctions described herein. In one further example, the controller 52includes a programmable logic controller with a touch-screen for userinput and display of status data. For example, the screen maysimultaneously show multiple fluid levels of the equipment that is beingserviced.

When in operation, the integrated fuel cap sensors 50 are mounted onrespective fuel tanks of the pieces of equipment that are subject to thehot-refueling operation. The hoses 40 are connected to the respectiveintegrated fuel cap sensors 50. Each integrated fuel cap sensor 50generates signals that are indicative of the fuel level in the fuel tankof the piece of equipment on which the integrated fuel cap sensor 50 ismounted. The signals are communicated to the controller 52.

The controller 52 interprets the signals and determines the fuel levelfor each fuel tank of each piece of equipment. In response to a fuellevel that falls below a lower threshold, the controller 52 opens thecontrol valve 44 associated with the hose 40 to that fuel tank andactivates the pump or pumps 30. The pump or pumps 30 provide fuel flowinto the manifolds 38 and through the open control valve 44 and reel 42such that fuel is provided through the respective hose 40 and integratedfuel cap sensor 50 into the fuel tank. The lower threshold maycorrespond to an empty fuel level of the fuel tank, but more typicallythe lower threshold will be a level above the empty level to reduce thepotential that the equipment completely runs out of fuel and shuts down.The controller 52 can also be programmed with a failsafe measure relatedto the operation of the fuel cap sensors 50. As an example, once acontrol valve 44 is open, if the controller 52 does not detect a changein fuel level from the fuel cap sensor 50 associated with the controlvalve 44 within a preset time period, the controller 52 shuts the pump30 off and closes the control valve 44. Thus, if a hose 40 were torupture, spillage of fuel is limited to the volume of fuel in the hose40. For instance, the preset time period may be three seconds, sixseconds, ten seconds, or fifteen seconds, which may limit spillage toapproximately fifteen gallons for a given size of hose.

The controller 52 also determines when the fuel level in the fuel tankreaches an upper threshold. The upper threshold may correspond to a fullfuel level of the fuel tank, but more typically the upper threshold willbe a level below the full level to reduce the potential for overflow. Inresponse to reaching the upper threshold, the controller 52 closes therespective control valve 44 and ceases the pump or pumps 30. If othercontrol valves 44 are open or are to be opened, the pump or pumps 30 mayremain on. The controller 52 can also be programmed with an electronicstop failsafe measure to prevent over-filling. As an example, once anupper threshold is reached on a first tank and the control valve 44 isclosed, but the pump 30 is otherwise to remain on to fill other tanks,if the fuel level continues to rise in the first tank, the controller 52shuts the pump 30 off.

Multiple control valves 44 may be open at one time, to provide fuel tomultiple fuel tanks at one time. Alternatively, if there is demand forfuel from two or more fuel tanks, the controller 52 may sequentiallyopen the control valves 44 such that the tanks are refueledsequentially. For instance, upon completion of refueling of one fueltank, the controller 52 closes the control valve 44 of the hose 40associated with that tank and then opens the next control valve 44 tobegin refueling the next fuel tank. The controller 52 may perform thefunctions above while in an automated operating mode. Additionally, thecontroller 52 may have a manual mode in which a user can control atleast some functions through the PLC, such as starting and stopped thepump 30 and opening and closing control valves 44. For example, manualmode may be used at the beginning of a job when initially filling tanksto levels at which the fuel cap sensors 50 can detect fuel and/or duringa job if a fuel cap sensor 50 becomes inoperable. Of course, operatingin manual mode may deactivate some automated functions, such as fillingat the low threshold or stopping at the high threshold.

In addition to the use of the sensor signals to determine fuel level, oreven as an alternative to use of the sensor signals, the refueling maybe time-based. For instance, the fuel consumption of a given piece ofequipment may be known such that the fuel tank reaches the lowerthreshold at known time intervals. The controller 52 is operable torefuel the fuel tank at the time intervals rather than on the basis ofthe sensor signals, although sensor signals may also be used to verifyfuel level.

The controller 52 also tracks the amount of fuel provided to the fueltanks. For instance, the register 34 precisely measures the amount offuel provided from the pump or pumps 30. As an example, the register 34is an electronic register and has a resolution of about 0.1 gallons. Theregister 34 communicates measurement data to the controller 52. Thecontroller 52 can thus determine the total amount of fuel used to veryprecise levels. The controller 52 may also be configured to provideoutputs of the total amount of fuel consumed. For instance, a user mayprogram the controller 52 to provide outputs at desired intervals, suchas by worker shifts or daily, weekly, or monthly periods. The outputsmay also be used to generate invoices for the amount of fuel used. As anexample, the controller 52 may provide a daily output of fuel use andtrigger the generation of an invoice that corresponds to the daily fueluse, thereby enabling almost instantaneous invoicing.

For diesel fuels used in re-fueling operations, others fuels, or otherliquids, additives may be used to modify one or more properties of thefuel or liquid. Examples based on diesel fuels may include additivesthat modify handling, gelling, thermal stability, engine protection, andcombustion. Example handling additives may include additives that modifyfreezing, flow, clouding, foaming, static electricity, dyes, odorants,deodorants, and the like. Example stability additives may includeanti-oxidants, metal deactivators, biocides, dispersants, and the like.Example engine protection additives may include corrosion inhibitors,cleaners, lubricants, and the like. Example combustion additives mayinclude ignition modifiers, such as cetane boosters, smoke suppressants,catalysts, and the like.

The fuel, as-received, may not initially include such additives.Although such additives may, in some cases, be included during refiningor prior to delivery of fuel to the site, not all customers may want toincur the expense of the additive, nor may such additives be needed orrequired for a particular operation. In order to provide such additiveson-site and on-demand, as customers or operations may require, thestation 20 includes an additive injector 60 (FIG. 2) fluidly connectedwith the delivery system of the station 20 and operable to introducecontrolled amounts of an additive into the delivery system. The pump(s)30, manifold(s) 38, hoses 40, reels 42, control valves 44, and fuel capsensors 50 collectively make up the delivery system of the station 20.

The additive injector 60 may be mounted inside the trailer 22, such ason one of the side walls W1/W2. As shown, the additive injector 60 isfluidly connected with a container 62 that contains an additive 64. Inthis example, the container 62 is separate from the station 20, althoughit may alternatively be inside or mounted inside the trailer 22. Theadditive injector 60 is also fluidly connected, by delivery line 66, tothe fuel line 32. The delivery line 66 may be a flexible hose, hardpiping, or the like. In this example, the delivery line 66 opens intothe fuel line 32 at a location between the pump(s) 30 and themanifold(s) 38. In this case, where there are two manifolds 38, thedelivery line 66 opens into the fuel line 32 at a location upstream froma split in the fuel line 32 to each manifold 38. This ensures that theadditive 64 is distributed to both manifolds 38.

In this example, the additive injector 60 is or includes a meteringpump. A metering pump moves a precise volume of fuel or liquid in aspecified time period to provide a controlled volumetric flow rate. Theamount of the additive 64 can thus be precisely controlled, monitored,and tracked. Example metering pumps may include, but are not limited to,piston pumps, diaphragm pumps, and parastaltic pumps.

The metering pump may further be a variable speed metering pump, thespeed of which can be adjusted to change and control the amount ofadditive introduced into the delivery system. In this regard, themetering pump can have an integrated controller that can be used toprogram, adjust, and control introduction of the additive. Additionallyor alternatively, the metering pump may be in communication with thecontroller 52, which may control operation of the metering pump.

The metering pump may introduce the additive 64 continuously or bybatch. For continuous introduction the integrated controller orcontroller 52 operates the metering pump to continuously introduce,i.e., inject, the additive 64 into the delivery system when the pump orpumps 30 are active. For instance, as one or more tanks are beingfilled, the additive 64 is injected so that the fuel delivered to thetanks has a known, controlled amount of the additive 64. The timeframeover which the additive is injected is equal to or substantially equalto (within about 10%) the timeframe over which the tank is filled. Forbatch introduction, the integrated controller or controller 52 operatesthe metering pump to introduce a defined dose amount of the additive 64over a defined timeframe. For instance, as a tank is being filled, thedefined dose of the additive 64 is injected so that the tank has aknown, controlled amount of the additive 64. The timeframe over whichthe dose is injected is less than the timeframe over which the tank isfilled.

In one further example, the integrated controller or controller 52includes a memory that is used to record how much of the additive 64 isdelivered into the delivery system. In this regard, the integratedcontroller or controller 52 can be used to track the amount of additive64 used over a time period to generate invoices for the amount used. Asan example, the integrated controller or controller 52 may provide adaily output of additive use and trigger the generation of an invoicethat corresponds to the daily use, thereby enabling almost instantaneousinvoicing.

FIG. 5 illustrates another example of the station 20. In this example,rather than the delivery line 66 of the additive injector 60 openinginto the fuel line 32, the delivery line 66 opens into the manifold 38.In this regard, if more than one manifold 38 is used, the additiveinjector 60 may also be connected to open into the other manifold 38.Alternatively, the additive injector 60 may open into only one of themanifolds 38, while the other manifold 38 does not have the additive 64.Of course, an additional additive injector 60 could be provided andfluidly connected with the other manifold 38 so that both manifolds canprovide fuel with the additive 64.

Although a combination of features is shown in the illustrated examples,not all of them need to be combined to realize the benefits of variousembodiments of this disclosure. In other words, a system designedaccording to an embodiment of this disclosure will not necessarilyinclude all of the features shown in any one of the Figures or all ofthe portions schematically shown in the Figures. Moreover, selectedfeatures of one example embodiment may be combined with selectedfeatures of other example embodiments.

The preceding description is exemplary rather than limiting in nature.Variations and modifications to the disclosed examples may becomeapparent to those skilled in the art that do not necessarily depart fromthis disclosure. The scope of legal protection given to this disclosurecan only be determined by studying the following claims.

What is claimed is:
 1. A distribution station comprising: a mobiletrailer; a delivery system including, a pump; a manifold connected withthe pump; reels connected with the manifold; hoses connected,respectively, with the reels; valves, each said valve being situatedbetween the manifold and a respective different one of the hoses; fluidlevel sensors, each said fluid level sensor being associated with arespective different one of the hoses; and an injection system includinga controller and an additive injector connected with the deliverysystem, the controller configured to adjust an amount of an additivethat the additive injector introduces into a fluid flowing in thedelivery system as the delivery system dispenses the fluid from at leastone of the hoses.
 2. The distribution station as recited in claim 1,wherein the additive injector is fluidly connected to the deliverysystem by a fluid delivery line, the fluid delivery line opening intothe delivery system at a location between the manifold and the pump. 3.The distribution station as recited in claim 2, wherein the additiveinjector is fluidly connected to the delivery system by a fluid deliveryline, the fluid delivery line opening into the delivery system at themanifold.
 4. The distribution station as recited in claim 1, wherein theadditive injector includes a metering pump, the additive injector isfluidly connected to the delivery system by a fluid delivery line, andthe fluid delivery line opens into the delivery system at a location atthe manifold or between the manifold and the pump.
 5. The distributionstation as recited in claim 1, further comprising fuel at least in themanifold.
 6. The distribution station as recited in claim 1, wherein theadditive injector includes a variable speed metering pump.
 7. Thedistribution station as recited in claim 1, wherein the fluid levelsensors are in fuel caps that are respectively connected at ends of thehoses.
 8. A distribution station comprising: a mobile trailer; adelivery system including, a pump; a manifold connected with the pump;reels connected with the manifold; hoses connected, respectively, withthe reels; valves, each said valve being situated between the manifoldand a respective different one of the hoses; fluid level sensors, eachsaid fluid level sensor being associated with a respective different oneof the hoses; and an injection system including a controller and anadditive injector connected with the delivery system, the controllerconfigured to operate the additive injector and introduce a defined doseof an additive into fluid in the delivery system over a timeframe thatis less than a timeframe over which at least one fluid tank is filledwith the fluid containing the defined dose.
 9. The distribution stationas recited in claim 8, wherein the additive injector includes a meteringpump.
 10. The distribution station as recited in claim 8, wherein thecontroller is configured to record how much of the additive is deliveredinto the delivery system.
 11. The distribution station as recited inclaim 8, wherein the additive injector is fluidly connected to thedelivery system by a fluid delivery line, the fluid delivery lineopening into the delivery system at a location between the manifold andthe pump.
 12. The distribution station as recited in claim 8, whereinthe additive injector is fluidly connected to the delivery system by afluid delivery line, the fluid delivery line opening into the deliverysystem at the manifold.
 13. The distribution station as recited in claim8, wherein the additive injector includes a variable speed meteringpump.
 14. The distribution station as recited in claim 13, wherein thefluid level sensors are in fuel caps that are respectively connected atends of the hoses.